Method of making two-ply fabrics



(Specimens.)

T. B. DOR'NAN.

METHOD OP MAKING TWO PLY FABRIC.

' No. 438,065. Patented Oct. 7, 1890.

f7 f/f' /5 a W @uw NITED STATES ATENT METHOD OF MAKING TWO-PLY FABRICS.

SPECIFICATION forming part of Letters Patent No. 438,065, dated October 7, 1890.

Application frledNovember 27, 1889. Serial No. 331,742. (Specimens.)

To all whom. it may concern:

Be it known that I, THOMAS BENTON Don- NAN, a citizen of the United States, residing at Philadelphia, in the county of Philadelphia and State of Pennsylvania, have invented certain new and useful Improvements in the Method of Making Two-Ply Fabrics, of which the following is a full, clear, and exact specication, reference being had to the accompanying drawings, which form a part hereof.

The present invention relates to the fabric known in the market as two-ply-ingrain-carpet fabric, and it has for its object to produce a more closely-knit and more durable fabric than any heretofore known ,while maintaining the characteristic advantages of two- `ply ingrain carpet, among them the advantages of double face and of cheapness of production, and also io produce more acceptable and purer color effects in the pattern in a fabric, showing less grinning or gazing of the back surface through the face than usual heretofore.

The invention consists of the method hereinafter described and claimed.

Heretofore in the manufacture of two-ply ingrain carpet it has been the practice to introduce the weft-threads in the definite order of one weft-thread in one ply--as, say, the ground ply-then a weft-thread in the other ply, the figure ply, then a weft-thread in the ground ply, then one in the ligure ply, and so on throughout the entire fabric; and the journals of the loom have been raised in the -same definite order, to wit: first a journal carrying warp of the ground ply, then a journal carrying warp of the iigure ply, then one carrying warp of the ground ply, then of the figure ply, and so on throughout the entire operation of weaving; and the lifter-boards of the jacquard have been raised in the same definite order, to wit: first the lifter-board carrying warp of the figure ply, then the lifter-board carrying warp of the ground ply, then the former again, then the latter, and so on to the end of the weaving. WVith such a method of weaving the diiferent constructions of weave which can be and which have heretofore been produced in two-ply ingrain carpets are shown in Figure l of the accompanying drawings. In this figure the three diagrams shown-*marked respectively, A, B,

and G-are diagrams of longitudinal sections cut through the carpet at three different points in its width, the cuts being made in a direction parallel to the warp-threads, and the diagrams all showing sections of different parts of the same weft-threads at different parts of their length, and also showing the four Warp-threads next adjacent to the cut or place of section. A representst-he bagweave fabric commonly known as ground or figure If one sideis ground, the reverse is figure, and vice versa. B represents the solid-weave fabric commonly known as shotabout. Either side indifferently is called shot-about. C represents the solid-weave fabric commonly known as mate-thread. Either side is mate-thread. The numerals 1 to 24, inclusive, show the order of insertion of the weft-threads and also show by identity of number the identity of the weft-threads in the three different sectional views given. The letters W, R, O, and B on the weft-threads indicate, Illustratively, the colors they would have in practice, and the letters w, r, o, and b on the warp threads indicate the corresponding colors they would ordinarily have in practice.

In carrying out my invention I insert the weft-threads in a different order or sequence, to wit: first a weft-thread in one ply-say the ground ply-then a second weft-thread in the same ply, then a weft-thread in the figure ply, then a second weft-thread in the figure ply, then a weft-thread in the ground ply, then a second one in the ground ply, then one in the ligure ply, then a second one in the figure ply, and so on throughout the weaving, and I change the arrangement of the journallifting devices, so as to raise irst a journal carrying warp of the ground ply and then the other journal carrying warp of the ground ply and then a journal carrying Warp of the gure ply, and then the other journal carrying Warp of the iigure ply, and so on', and I change the arrangement of the lifting devices of the jacquard lifter-boards, so as to raise those lifterboards as follows: first (in the case supposed) the lifter-board carrying warp of the ligure ply, then the same lifter-board again, then the lifter-board carrying warp of the ground ply, then the same lifter-board again, then the first lifter-board twice in succession, then IOO the second twice, and so on. As usual heretofore, I raise bymeans of the proper journal the warp-threads of the same ply and preferably of the same color as the weft-thread which is about to be thrown, and simultaneously raise or leave down by means of the jacquard all the warp-threads of the other ply, thereby sending to the bottom face or to the top face of the carpet, as desired, the weft-thread that is about to be thrown, and in every case covering or binding it on top with warp-threads of the same ply and preferably of the same color; and, as common heretofore, I employ a card in the Jacquard machine for every pick of the loom; but I change the order of those cards in the lacing, or, what isvthe same thing, I change the manner of cutting the cards to conform tofmy new order of i-nserting the weft-threads, and cut the first card for a ground weft, (in the case supposed,) the second for a ground weft, the third for a figure weft, the fourth for a iigure weft, the fifth for a ground weft, the sixth for l a ground weft, and so on.

With this improved method of weaving the various constructions of weave that can be produced and are produced in bringing the dilferent color effects to the face are shown in the drawings, Fig. 2, in which the three several diagrams D, E, and F'respectively represent, as before, three longitudinal sections cut parallel with the warp-threads through different parts of the same weft-threads. The numerals on the weft -threads indicate the order of introduction of the weft-threads and indicate-by identity of number the identity of weft-threads in the different diagrams. W OR B indicate, illu stratively, the colors white, olive, red', black of the weft-threads, and w o r b indicate the colors white, olive, red, black of thewarp-threads; Of course the reverse of each one of these fabrics may be produced.

The construction of weave shown in Fig. 2, diagram F, is in and of itself' a new fabric, and the combination of that fabric, or ofits reverse, or of both, with the construction of weave shownin Fig. 2, diagram E, or its reverse, or both, and with or without the construction of weave shownv in Fig. 2, diagram D, or its reverse, or both,A all in a patterned fabric, in which four or more differently-colorded weft-threads successively thrown are employed, is a new composite fabric, combining more acceptable and purer color effectsin the pattern than heretofore with a closer-knit structure and more durable wearing qualities.

The fabric F of Fig. 2, separately considered, is a double-ply solid-weave two-ply ingrain-earpet fabric, in which each face is made up of successively-thrown weft-threads, as WV B W B W, &c., and O R O R, rbc., andi'n which the stuffer-warp threads 0 and r, which make and keep it double-ply, lie along the middle of the fabric, and in which the adjacent binding-warp threads w and b crossV alternately from face to face, binding the wefts both of the face and of the back, but in such a peculiar way that one weft-threadsay weft-thread No. 4 B of the face-is bound and held by the warp-thread b in a loop projecting backward, as appears in the diagram F, and the next-succeeding weft-thread, No. 5 W of the face, is bound and held by the adjacent and oppositely-moving warp-thread w in a loop projecting forward and crossing the backwardly-projecting loop of the black warp, as appears in Fig. 2 at F. Similarly all the black weft-threads are bound on the face by backwardly-projecting loops of the black warp-threads, and all the white weft-threads by forwardly-projecting loops of the white warp-threads; and on the back all the olive `weft-threads are bound by backwardly-proj ecting loops of the white warps, and all the red weftthreads by forwardly-projecting loops of the black warps, the loops crossing each other in the solid fabric. By this peculiar construction of weave a better-wearing fabric is produced for under-foot use than has existed in ingrain fabrics heretofore.

In the combination'fabric consisting of the parts F and E, with or without the parts D, a range of color effects is attained with the use of only four weft colors which is equal tothat attained by any processes in use for the manufacture of two-ply ingrain carpets, and', in addition, in the parts E color effects are attained by me in solid weave which are practically as pure and as free from the grinning and gazing through of the other face of the goods as has heretofore characterized only the bagweave effectsl ground and ligure and which has never been true heretofore of solid weave in two-ply ingrain carpets, either shot-about solid weave or mate-thread solid weave. The latter two have always developed more or less gazing, by reason of the perceptible arrangement of the weft-threads in pairs or couples close together on the face with` spaces or intervals between the couples. There are practically no such spaces and no such coupling in the case of the old bag weave, A, Fig. l, nor is there in the case of my bag weave, D, Fig. 2, or of my solid weave E, although it exists to a small extent in the case of my solid weave F, as it does in the cases of shot-about and mate-thread B and C. The lsimilar order of introduction of the weft-threads that appear on the face in E and A--to wit, Jrst, third, fth, seventh, rc-makes E'similar to A in the beating up of its wefts, as shown in the drawings, and the warping of E, like the warping of A, tends to retain the weft-threads in that regular and equidistant relationship tov each other. D is similar to C in the order of introduction of the weft-threads which forni its face; Abut while the warping of C tends to retain the weft-threads in pairs with gaps between the pairs, as shown in the drawings, the warping of' .D tends to rearrange the wefts in the regular and equidistant relationship to each other which characterizes A andV E. Thus a larger proportion of my new combination fabric will show pure color effects than IIO ISO

has been possible or has been attained heretofore. Comparing E and C, the difference in the order of introduction of the weftthreads causes the dierence in the beating up of the weft-threads (shown in the drawings) and the warping tends to preserve that dierence.

I do not herein claim the fabric herein de? following order, to wit: two successively belonging to one ply and then two successively belonging to the other ply; employing warps in four divisions, two for each ply, and raising the same in the following order for the formation of the plies, to wit: the two divisions for one ply successively, then the two divisions for the other ply successively; and manipulating the warps for the production of the pattern in the following order, to wit: the warps of one ply twice successively, and then the warps of the other ply twice successively; and employing a pattern-card for each separate weft or pick of the loom, substantially as and for the purposes set forth.

THOMAS BENTON DORNAN. Witnesses:

MILLARD F. SHOCK, E. WILBRAHAM. 

